Apparatus for catalytic distillation processes

ABSTRACT

The invention disclosed relates to catalytic distillation column internals providing improved liquid and catalyst contacting for simultaneous catalytic reaction and separation of the reaction mixture. The invention provides an improved catalytic distillation system providing optimum balance of catalytic reaction and mass transfer steps, wherein distribution, mixing and application of liquid to the reaction zone and separation zones is better controlled and more uniformly applied. At least one catalyst bed is situated in at least one receiving pan of a distillation tray so that said tray performs the functions of both of the reaction section and the separation section of the catalytic distillation column simultaneously within a stage.

BACKGROUND OF THE INVENTION

The invention relates generally to an apparatus for use in catalytic distillation processes, and more particularly to column internals for catalytic distillation processes. The present invention is particularly suited for column internals utilizing catalyst beds and trays with multiple stage sections.

Catalytic distillation processes are processes in which at least one chemical reaction is carried out in the presence of at least one solid catalyst. The chemical reaction occurs simultaneously by distillation with a separation of the reaction mixture obtained within one vessel. Several types of apparatuses have been described for use in a variety of catalytic distillation processes.

The key part of developing catalytic distillation technology is the design of internal elements or tower internals for the catalytic distillation columns. The functions of column internals are to carry out both the catalytic reaction and mass transfer simultaneously. In the past fifteen years, numerous patents have been awarded for the new design of the internals. They can be classified as follows:

1. Cloth Belt (U.S. Pat. No. 4,215,011). The catalyst is sealed within a cloth belt. The belt is then wrapped in an open mesh knitted stainless steel wire. Liquid can penetrate into and flow out from the catalyst through the cloth. The liquid wetted surface of the cloth belt provides the vapor-liquid interfacial area for mass transfer.

The mass transfer efficiency for this type of catalyst unit is very low because of the low interfacial area. The effectiveness of the catalyst inside the belt may change from location to location because of the different liquid residence time within the cloth. This reduces the overall system efficiency.

2. Catalyst Container Held on a Tray (U.S. Pat. Nos. 4,536,373, 4,439,350, 5,447,609, 5,449,501, 5,776,320, 5,792,428, 5,888,355 and 6,045,762). One type of this catalytic distillation unit consists of a normal distillation tray and a parallel array of rectangular tubes (troughs) filled with a catalyst. The tubes (troughs) are constructed with metal screen and closed at both ends. The parallel tubes (troughs) may be supported above a distillation tray but should be located within a froth zone when the column is in operation. The liquid flows across the tray in either parallel or at right angles to the tubes (troughs).

Another type of this unit consists of a normal distillation tray and closed porous containers containing catalyst. The containers are installed above or on the distillation tray in the tower. At least one tray may be combined with a packed catalyst bed. Another type of unit includes catalyst containing reaction zones in which liquid phase rises through a catalyst bed before exiting downward from an opening at the top of the reaction zone.

The structure of these units is usually quite complex, thus leading to a greater cost in the overall system. The catalyst quantity that can be loaded is also limited by both volume and spacing. It is not suitable if the catalytic reaction step is slow because the reaction rate may not be matched with the mass transfer rate and will lower the overall efficiency of the system.

3. Packings. Random packings (U.S. Pat. Nos. 4,443,559, 5,057,468, 5,275,790, 5,262,012, and 5,189,001), e.g. Raschig rings, can be made of a polymer catalyst such as ion exchange resins. The random packing in the column acts as both a catalyst and a mass transfer device. The random packing can also be made from rigid containers having a volume substantially smaller than the volume of a reactive distillation column.

The catalyst can be loaded into the container. Openings in the containers are provided to allow vapor and liquid passage into and out of the containers. The surfaces of the containers provide the necessary vapor-liquid contact for the distillation. The rigidity of the containers provides for the spacing of the structures and the necessary free space for the distillation or mass transfer.

Another type of this unit consists of a catalyst component and a resilient component intimately associated therewith. The resilient component has at least about 70% volume open space and is present with the catalyst component in an amount such that the catalyst distillation structure consists of at least 10% volume open space.

Structured Packings (U.S. Pat. Nos. 5,073,236, 5,235,102, and 5,348,710) are constructed with corrugated screen envelope with catalyst filled inside. Each envelope consists of two parallel layers of crimped screen, roughly 6.25 centimeters (1 ft.) square, which are sealed at the edges. The envelopes are stacked and bound to make “bricks”, which in turn are stacked to fill the column. The packing can also be fabricated in rigid, cellular monoliths or in a rigid, cellular monolith coated with a catalytically-active material.

Liquid holdup or the time the liquid is retained within this type of column internals is low. Therefore, it is not suitable for a slow reaction. Like cloth belts, the effectiveness of the catalyst may change from surface to the inside because of the different liquid residence time within the packing. Additionally, the complex nature of the screens and packing leads to an increased cost of the internals and system.

4. Tray Plus Fixed Bed of Catalyst (U.S. Pat. Nos. 5,130,102, 5,368,691, 5,013,407, 5,026,459 and 6,441,252). In these catalytic distillation units, the reactive zone consists of alternate beds of catalyst and catalyst-free distillation zones. Passageways may be provided for a vapor phase in the fixed bed. Distillation zones contain normal distillation trays and liquid distribution plates.

The structures of these units are typically complex and relatively high in cost. The liquid flow pattern may be far from plug flow or single direction flow. Therefore, the efficiency could be low.

5. Conventional Distillation Tray with Catalyst Placed in the Downcorner (U.S. Pat. Nos. 3,579,309, 5,277,847, 3,629,478, and 3,634,535). In these units, downcorners attached to the conventional trays are filled with catalyst, which serve as a reaction zone, and the trays act as a separation zone.

In these units, the catalyst may not be exposed to liquid, thus reducing its activity. Also, loading is limited by the downcorner size. It is not suitable for slow reaction processes. The catalyst bed may pose a restriction to the liquid flow in the downcorner which may cause a backup of liquid onto the tray, thereby reducing efficiency.

6. Fixed Catalyst Bed with a Distribution Element (U.S. Pat. No. 5,523,062). In this arrangement, a corrugated plate having openings only at the peaks or valleys of the corrugation is used as a distribution element for the fixed catalyst bed. The plate and fixed bed are installed alternatively. The plate has little or no contribution to mass transfer.

The liquid distribution to the lower catalyst bed can deteriorate if the plate is not properly installed. Radial mixing of liquid in the column is minimal. All of these beds may cause great uncertainty in the operation of such a catalytic distillation unit. For the catalyst part, the same disadvantages exist as packings stated above in (3). Steps in a complex process may be conducted as discreet catalytic distillation processes in a sequence of units (U.S. Pat. Nos. 6,294,684, 6,407,300 and 6,767,517).

It will be apparent that each of the different types of units has their advantages and disadvantages. However, none the above-described systems provides structures that may easily be adapted to couple a specific reaction with a desired separation, i.e. for any given catalytic reaction there is a corresponding separation rate. There is a need for both improved distribution of the liquid phase and improved contact of said liquid phase with the catalyst during catalytic distillation.

BRIEF SUMMARY OF THE INVENTION

The invention provides an apparatus consisting of a column for catalytic distillation processes in which at least one catalyst bed is situated within receiving pans of one or more trays so that said trays perform the functions of both of the reaction section and the separation section of the catalytic distillation column.

Distribution of liquid phase at a stage within a catalytic distillation unit may be effected by tray or by packing. Distribution by tray is the simplest and the design procedure is known in the art. The present invention addresses the need for improved distribution of liquid phase and thereby improved contact of said liquid phase with catalyst in the presence of vapor phase.

In one embodiment of the present invention, a catalytic distillation apparatus is disclosed comprising a vessel, at least one support deck in at least a portion of the vessel; the support deck having a separation portion, a mixing portion, and a reaction portion, for simultaneous catalytic reaction and fractional distillation. The catalytic distillation apparatus further comprises the separation portion being a perforated tray for fractional distillation. In other embodiments of the invention, the separation portion may be a valve or sieve tray or any other suitable fractional distillation apparatus. Additionally, packing structures may be used for fractional distillation within the separation section.

The catalytic distillation apparatus further comprises a mixing surface having at least one feed pipe through which a liquid reaction mixture descends from a mixing surface of the mixing portion to the reaction portion to an at least one receiving pan below the mixing surface. The receiving pan has a catalyst for a catalytic reaction. Within the receiving pan, a distributor is installed for uniform distribution of liquid within the reaction portion. The reaction portion further includes a pressure equalizer to balance pressure between the reaction portion and the separation portion.

The reaction portion may also be designed to have a directional flow seal to balance pressure and distribute liquid from the support deck such that movement of vapor in a countercurrent direction to that of the liquid through the reaction section is prevented. The directional flow seal functions to balance pressure and distribute liquid from the support deck.

The separation section has at least one vapor riser extending through the mixing deck, the vapor riser extending above the mixing deck so that liquid does not flow downward through said vapor riser. The vapor riser also functions to balance the pressure between the reaction and separation sections.

Also disclosed is a kit for revamping a distillation column comprising at least one support deck, the support deck having a separation portion, a mixing surface and a reaction portion, for simultaneous catalytic reaction and fractional distillation.

In another embodiment of the invention, a process for catalytic distillation is disclosed comprising feeding a liquid to a vessel having at least one support deck in at least a portion of the vessel, the support deck having a separation portion, a mixing surface and a reaction portion, for simultaneous catalytic reaction and fractional distillation. Liquid is then mixed on a mixing surface and fed to the reaction portion. The liquid is reacted with a catalyst through a catalytic reaction in the reaction portion and a concentrated product is fractionated.

The process for catalytic distillation includes feeding the liquid to the reaction portion such that it is even distributed through the reaction portion. Fractionation of the concentrated product may be through a valve or sieve tray. The fractionating of the concentrated product may also be through a packed bed. During the fractioning, mixing and reacting, the process for catalytic distillation within the catalytic distillation column further comprises balancing a pressure between the reaction portion and the separation portion.

In an alternative embodiment of the invention, internals for a catalytic distillation apparatus comprising a sequence of spaced apart trays, each tray having a reaction section, a mixing section and a separation section is disclosed. The reaction section has at least one feed pipe into which liquid reaction mixture descends from a liquid mixing deck into receiving pans situated below the liquid mixing deck and at least one catalyst chamber situated within the receiving pans.

The catalyst chamber contains at least one catalyst bed and an open portion through which the liquid reaction mixture is capable of flowing in an even and distributed pattern. The feed pipe extends to a depth within the catalyst bed so that liquid reaction mixture enters the catalyst chamber at a lower part of the catalyst bed, then rises within the catalyst bed to the open portion above said catalyst bed.

The catalyst chamber further includes at least one reaction product outlet through the sidewall of the catalyst chamber, situated above the catalyst bed, the reaction product outlet being in communication with the open portion of the catalyst chamber. Liquid reaction product that has risen through the catalyst bed exits from the reaction section through the reaction product outlet to the separation section.

The separation section has a rising vapor channel passing vertically through each tray, with vertical sidewalls extending along each side for a full length of the vapor channel. Perforated horizontal plates through which vapor can rise from one tray to another tray immediately above for mass transfer. Alternatively, a packed material may be placed in the vapor channel for vapor-liquid exchange.

The separation section may also have liquid transport channels along the sidewalls of the vapor channel, an inlet area, horizontal plates perforated with a plurality of holes, and a downcorner. The liquid transport channels extend from the reaction product outlet of the reaction section to the inlet area of the separation section. Each horizontal plate extends across the width between sidewalls of the vapor channel and along the length of the vapor channel between the inlet area and the downcorner.

The downcorner has a weir situated toward the end of the plate adjacent the downcorner, the weir being sized so as to maintain a depth of liquid reaction mixture above the plate as said liquid reaction mixture flows along said plate. Vapor rising from the tray below and through the plate forms bubbles in the liquid in a bubbling area immediately above said plate and the liquid reaction mixture flowing over the weir descends the downcorner and from the downcorner flows onto the liquid mixing deck of the reaction section of the tray below.

The catalytic distillation column may also be designed with a positive seal between the reaction section of one tray and the separation section of the tray situated immediately below. The positive seal includes a sheet within the rising vapor channel extending away from the sidewall and downward from a position on the sidewall above the reaction product outlets from the reaction section. The bottom of the sheet is situated within the corresponding liquid transport channel and extends along its entire length, with the effect that, when liquid reaction mixture is flowing within the full length of the liquid transport channel, movement of vapor in a countercurrent direction to that of the liquid through reaction product outlet is prevented.

In another embodiment of the invention, a catalytic distillation tray has at least one separation section packed with a packing. The packing is positioned relative to at least one catalyst chamber such that the liquid reaction mixture exiting from the open portion of the catalyst chamber through the reaction product outlet into the separation section descends onto a liquid distributor that distributes said liquid reaction mixture across the top surface of the packing. At least one vapor riser extends through the liquid mixing deck and above the liquid mixing deck and is designed such that the liquid reaction mixture does not flow downward through said vapor riser.

These, and other, embodiments of the invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating multiple embodiments of the invention and numerous specific details thereof, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the invention without departing from the spirit thereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

These and the other features of the invention will become more apparent from the following description in which reference is made to the appended drawings, wherein:

FIG. 1, is a schematic diagram of a conventional catalytic distillation column.

FIG. 2 is a top view of a tray in one embodiment of a catalytic distillation apparatus according to the present invention, with positive seal.

FIG. 3 is a side view of a section, labeled X-X in FIG. 2, of a tray in an embodiment of the catalytic distillation apparatus.

FIG. 4 is a top view of a tray in an alternate embodiment of a catalytic distillation apparatus according to the present invention, without positive seal.

FIG. 5 is a side view of a section, labeled Y-Y in FIG. 4, of an alternate embodiment of the catalytic distillation apparatus.

FIG. 6 is a side view of a section, labeled Z-Z in FIG. 4, of an alternate embodiment of the catalytic distillation apparatus.

FIG. 7 is a top view of a tray in another embodiment of a catalytic distillation apparatus according to the present invention, in which the tray has a packed catalyst bed and a separation section with packing.

FIG. 8 is a side view of a section, labeled W-W in FIG. 7, of a tray in another embodiment of the catalytic distillation apparatus.

FIG. 9 is a top view of a tray in another embodiment of a catalytic distillation apparatus according to the present invention, in which the tray has multiple packed catalyst beds and separation sections with packing.

FIG. 10 is a side view of a section, labeled V-V in FIG. 9, of a tray in another embodiment of the catalytic distillation apparatus.

FIG. 11 is a perspective view of a tray in one embodiment of a catalytic distillation apparatus of the present invention.

DESCRIPTION OF SPECIFIC EMBODIMENTS

For a detailed description of the preferred embodiments, the reader is referred to the attached figures wherein like components are given like numbers for ease of reference.

The present invention arose from the observation that there was pressure drop within a catalytic reaction section of a distillation column. Pressure drop resistance is present when liquid passes through a catalyst bed. By balancing the reaction chamber with the tray above, the pressure drop effect is reduced or minimized. There is extra pressure then available, thus increasing tray capacity and efficiency and increasing the overall efficiency of the column resulting in cost and energy savings.

Additionally, there was an observation that catalytic reaction stages were less efficient due to the bypass or plug flow of the catalyst bed. By directing liquid to the catalyst bed and having a more evenly distribution through the catalyst, the catalytic section of the column would be more efficient and have a greater capacity by having more catalytic reactions. Also, by having a continuous reaction where there was a fractionation, more complete mixing and then a more complete reaction, the column efficiency would be improved.

FIG. 1, is a schematic diagram showing a design for a catalytic distillation column 10 that will-be familiar to those skilled in the art. Catalytic distillation column 10 has a top 12, a bottom 14 and sidewalls 16 that enclose an inner compartment 18. Inner compartment 18 has an upper portion 20, a lower portion 22 and a central portion 24. Within inner compartment 18 there are at least one reaction section 26 and at least one separation section 28. When there is one reaction section 26 within inner compartment 18, said reaction section 26 may be located in lower portion 22 as shown in FIG. 1, or in upper portion 20 or in central portion 24, depending on the process for which catalytic distillation column 10 is used. When there is more than one reaction section 26 within inner compartment 18, said reaction sections 26 may be spaced apart. Separation section 28 shown in FIG. 1 contains trays 30 for enhancing contact between vapor phase and liquid phase components of the reaction mixture. It will be recognized that trays 30 in separation section 28 may be replaced by packing (not illustrated) that may be a random or a structured packing.

Representative embodiments of an improved catalytic distillation apparatus according to the present invention now will be described with reference to FIGS. 2 through 11. A portion of one embodiment of catalytic distillation column 110 is shown in FIGS. 2 and 3, a portion of another embodiment of catalytic distillation column 210 is shown in FIGS. 4 through 6, a portion of an alternate embodiment of catalytic distillation column 310 is shown in FIGS. 7 and 8 and a section of another embodiment of catalytic distillation column 410 is shown in FIGURES 9 and 10.

Catalytic distillation columns 110, 210, 310 and 410 share several features, and also share some features with a representative typical catalytic distillation column 10. The similar features that will be described for catalytic distillation column 110 will have the same reference numerals for descriptions of catalytic distillation column 210, catalytic distillation column 310 and catalytic distillation column 410.

In each of FIGS. 2 through 10, a lightly shaded broad arrow generally indicates the direction of flow of vapor 32 or vapor flow. A darkly shaded broad arrow generally indicates the direction of flow of liquid 34 or liquid flow.

Whereas a typical catalytic distillation column 10 as illustrated in FIG. 1 has the reaction section 26 and the separation section 28 in sequence and in distinct separate sections of the column, each of the representative embodiments of catalytic distillation columns 110, 210, 310, 410 of the present invention combines reaction section 26 and separation section 28 within at least one tray 30. In catalytic distillation columns 110, 210, 310, 410, at least one catalyst bed is situated in receiving pan of distillation tray 30.

The present invention provides for an improved liquid 34 and catalyst 38 contacting system for simultaneous catalytic reaction and separation of the reaction mixture in the embodiments of catalytic distillation columns 110, 210, 310, 410. The present invention provides a system wherein distribution and application of liquid 34 to reaction section 26 and separation section 28 is better controlled and more uniformly applied, and thereby providing an improved capacity and more efficient catalytic distillation system providing better coordination of the separation step with the catalytic reaction step.

Turning now to FIG. 2, a top view of a tray 30 within catalytic distillation column 110 according to the present invention is illustrated. Tray 30 has a separation or fractionation section near or at a portion above the midline of the tray, a mixing section near or at the midline of the tray and a reaction section near or at a portion below the midline of the tray.

The separation section includes at least one vapor channel 42. Vapor channel 42 extends horizontally across a width of catalytic distillation column 110, as illustrated in FIGS. 2, 4, 7 and 9. Vertical sidewalls 50 extend along each side for the full length of vapor channel 42. A series of horizontal plates 44 each having holes 46 extends across the width between sidewalls 50 of vapor channel 42. Sidewalls 50 have a height selected so as to maintain a depth of liquid 34 in a bubbling area 68 above plate 44.

Vapor channel 42 with plates 44 serves a similar function as separation section 28 shown in a typical catalytic distillation column 110 illustrated in FIG. 1. However, whereas typical catalytic distillation columns 10 have the reaction section 26 and the separation section 28 in sequence, the catalytic distillation column of the present invention combines reaction section 26 and separation section 28 within tray 30.

Inlet area 54 and a downcorner 56 are at opposed ends plate 44. Inlet area 54 is adjacent a portion of sidewalls 16 of catalytic distillation column 110 providing an inlet for the separation section. Downcorner 56 is adjacent to a portion of sidewalls 16 diametrically opposite to inlet area 54 providing an output from the separation section. A tray outlet weir 58 extends across an end 60 of plate 44. A downcorner outlet weir 62 extends between each end of tray outlet weir 58 and sidewalls 16 thus surrounding opening 66 of downcorner 56. A combination of tray outlet weir 58 and downcorner outlet weirs 62 also has a pre-designed height to help maintain a depth of liquid 34 in a bubbling area 68 above plate 44.

In the mixing section, tray 30 has a liquid mixing deck 48 which extends horizontally between an interior surface 52 of sidewalls 16 in catalytic distillation column 110. Liquid mixing deck 48 has at least one vertical feed pipe 70 to the reaction section below. In this embodiment of the invention, at least one vent 82 to the reaction section below may be included. Beneath the liquid mixing deck 48, there is a plurality of reaction product outlets 72 from the reaction section through which liquid 34 pours into a liquid transport channel 74 located below liquid mixing deck 48.

Referring to FIG. 3, a cross-section of tray 30 through X-X of FIG. 2 is illustrated. Tray 30 has at least one horizontal tray 30 is situated within catalytic distillation column 110. In one embodiment of the present invention, a sequence of spaced apart horizontal trays 30, each with a reaction section 26, mixing section and a separation section 28, is situated within the catalytic distillation column 110. Each tray 30 has a catalyst 38 contained within a catalyst chamber 40.

The separation section includes at least one vapor channel 42. Vapor channel 42 provides for a flow of vapor 32 passing vertically through tray 30, as illustrated in FIGS. 3 and 5. Vertical sidewalls 50 extend along each side for the full length of vapor channel 42. A series of horizontal plates 44 each having holes 46 extends across the width between sidewalls 50 of vapor channel 42. Sidewalls 50 have a height selected so as to maintain a depth of liquid 34 in a bubbling area 68 above plate 44.

Rising vapor 32 passes through holes 46, as illustrated in FIGS. 3 and 5, so that vapor 32 bubbles through liquid 34 that is flowing across plate 44 in bubbling area 68, as illustrated in FIGS. 2 through 5. Liquid 34 flows over downcorner outlet weirs and into a downcorner (not shown) and on to liquid mixing deck 48.

The mixing section has a liquid mixing deck 48 extending horizontally between an interior surface 52 of sidewalls 16 of catalytic distillation column 110 and each of opposed sidewalls of vapor channel 42. Liquid mixing deck 48 is situated at a level below the level of corresponding plate 44. Liquid mixing deck 48 has at least one vertical feed pipe 70 to the reaction section below. In this embodiment of the invention, at least one vent 82 to the reaction section below is included to balance pressure between the reaction section 26 and the separation section 28.

Liquid mixing deck 48 is situated directly above catalyst chamber 40 of the reaction section 26. Catalyst chamber 40 contains catalyst 38 for a catalytic reaction. Catalyst chamber 40 is positioned within receiving pan 36 to provide for an even distribution of liquid through the reaction section 26.

Liquid 34 flows through vertical feed pipes 70 extending from liquid mixing deck 48 into the catalyst chamber 40. Liquid 34 rises through bed of catalyst 38 within catalyst chamber 40 wherein the reaction mixture reacts catalytically. The level of liquid 34 in catalyst chamber 40 rises to an open portion 80 for liquid flow above catalyst 38, until it reaches a plurality of reaction product outlets 72. Liquid 34 then pours into a liquid transport channel 74.

Liquid 34 travels along liquid transport channel 74 to inlet area 54 of another tray 30 below that tray 30 through which it has just passed. Contact between liquid 34 and catalyst 38 is maximized as there are no bubbles of vapor 32 rising through catalyst chamber 40.

In an alternate embodiment of the invention demonstrating a reverse-flow within the column (not shown), liquid 34 may flow down through catalyst bed 38 within catalyst chamber 40 wherein the reaction mixture reacts catalytically. Liquid 34 is distributed above the catalyst bed 28, and passes uniformly through the catalyst bed 28. The liquid 34 then exits from a lower exit point close to the bottom of the catalyst chamber 40.

Referring to FIG. 3, one embodiment of catalytic distillation column 110 has a vertical sheet 76 extending downward from a position above reaction product outlets 72 on sidewalls 50 into the full length of liquid transport channels 74, thus effecting a positive seal preventing movement of vapor 32 in a countercurrent direction to that of liquid 34 through reaction product outlets 72. A vent 82 is provided to allow vapor to exit from open portion 80, thus preventing build up of pressure within open portion 80 resulting from the positive seal.

Turning now to FIG. 4, a top view of a tray 30 within catalytic distillation column 210 according to the present invention is illustrated. Tray 30 has a separation or fractionation section near or at a portion above the midline of the tray, a mixing section near or at the midline of the tray and a reaction section near or at a portion below the midline of the tray.

The separation section includes at least one vapor channel 42. Vapor channel 42 extends horizontally across a width of catalytic distillation column 210. Vertical sidewalls 50 extend along each side for the full length of vapor channel 42. A series of horizontal plates 44 each having holes 46 extends across the width between sidewalls 50 of vapor channel 42. Sidewalls 50 have a height selected so as to maintain a depth of liquid 34 in a bubbling area 68 above plate 44.

Inlet area 54 and a downcorner 56 are at opposed ends plate 44. Inlet area 54 is adjacent a portion of sidewalls 16 of catalytic distillation column 210 providing an inlet for the separation section. Downcorner 56 is adjacent to a portion of sidewalls 16 diametrically opposite to inlet area 54 providing an output from the separation section. A tray outlet weir 58 extends across an end of plate 44. A downcorner outlet weir 62 extends between each end of tray outlet weir 58 and sidewalls 16 thus surrounding opening 66 of downcorner 56. A combination of tray outlet weir 58 and downcorner outlet weirs 62 also has a pre-designed height to help maintain a depth of liquid 34 in a bubbling area 68 above plate 44.

In the mixing section, tray 30 has a liquid mixing deck 48 which extends horizontally between an interior surface 52 of sidewalls 16 in catalytic distillation column 110. Liquid mixing deck 48 has at least one vertical feed pipe 70 to the reaction section below. There are no vents 82 in this embodiment of the invention. Beneath liquid mixing deck 48, there is a plurality of reaction product outlets 72 through which liquid 34 pours into a liquid transport channel 74.

Referring to FIG. 5, a side view of section Y-Y of FIG. 4 of catalytic distillation column 210 is illustrated. In this embodiment of catalytic distillation column 210, there are no vertical sheets 76 extending into liquid transport channel 74. Instead, countercurrent flow of vapor 32 against the flow of liquid 34 in this embodiment of catalytic distillation column 210 is resisted by flow of liquid 34 through reaction product outlets 72 and the prevailing liquid pressure. This embodiment of catalytic distillation column 210 differs from catalytic distillation column 110 in that there is no positive seal at liquid transport channel 74, and there is no vent 82 from open portion 80 of the reaction section 26 of the catalytic distillation column 210 to the separation section 28.

Referring to FIG. 5, at least one horizontal tray 30 is situated within catalytic distillation column 210. In this embodiment of the present invention, a sequence of spaced apart horizontal trays 30, each with a reaction section 26, a mixing section and a separation section 28, is situated within the catalytic distillation column 210.

The separation section includes at least one vapor channel 42. Vapor channel 42 provides for a flow of vapor 32 passing vertically through tray 30, as illustrated in FIG. 3. Vertical sidewalls 50 extend along each side for the full length of vapor channel 42. A series of horizontal plates 44 each having holes 46 extends across the width between sidewalls 50 of vapor channel 42. Sidewalls 50 have a height selected so as to maintain a depth of liquid 34 in a bubbling area 68 above plate 44.

Rising vapor 32 passes through holes 46, as illustrated in FIG. 3, so that vapor 32 bubbles through liquid 34 that is flowing across plate 44 in bubbling area 68, illustrated in FIGS. 2 through 5. Liquid 34 flows over downcorner outlet weirs and into a downcorner (not shown) and on to liquid mixing deck 48.

The mixing section has a liquid mixing deck 48 extending horizontally between an interior surface 52 of sidewalls 16 of catalytic distillation column 110 and each of opposed sidewalls of vapor channel 42. Liquid mixing deck 48 is situated at a level below the level of corresponding plate 44. Liquid mixing deck 48 has at least one vertical feed pipe 70 to the reaction section below.

The reaction section of each tray 30 has a catalyst 38 contained within a catalyst chamber 40. Catalyst chamber 40 is positioned at receiving pan 36. Liquid mixing deck 48 is situated directly above catalyst chamber 40. Liquid 34 flows through vertical feed pipes 70 extending from liquid mixing deck 48 into catalyst chamber 40. Liquid 34 rises through bed of catalyst 38 within catalyst chamber 40 wherein the reaction mixture reacts catalytically. The level of liquid 34 in catalyst chamber 40 rises to an open portion 80 for liquid flow above catalyst 38, until it reaches a plurality of reaction product outlets 72 through which liquid 34 pours into a liquid transport channel 74.

Liquid 34 travels along liquid transport channel 74 to inlet area 54 of another tray 30 below that tray 30 through which it has just passed. Contact between liquid 34 and catalyst 38 is maximized as there are no bubbles of vapor 32 rising through catalyst chamber 40.

Turning now to FIG. 6, catalytic distillation column 210 is illustrated as a section Z-Z of FIG. 4. Horizontal tray 30 is situated within catalytic distillation column 210. In this embodiment of the present invention, a sequence of spaced apart horizontal trays 30 is situated within the catalytic distillation column 210. Each tray 30 has a catalyst 38 contained within a catalyst chamber 40. Catalyst chamber 40 is positioned at receiving pan 36.

Liquid mixing deck 48 extends horizontally between an interior surface 52 of sidewalls 16 of catalytic distillation column 210. Liquid flows from inlet area 54 along a plate toward downcorner 56. Liquid flows over downcorner outlet weirs 62 and on to liquid mixing deck 48 below. A combination of tray outlet weir 58 and downcorner outlet weirs 62 has a height designed to maintain a depth of liquid 34 in a bubbling area 68 above the plate.

Liquid mixing deck 48 is situated directly above catalyst chamber 40. Liquid flows through vertical feed pipes 70 extending from liquid mixing deck 48 into catalyst chamber 40. Liquid rises through bed of catalyst 38 within catalyst chamber 40 wherein the reaction mixture reacts catalytically. The level of liquid in catalyst chamber 40 rises to an open portion 80 for liquid flow above catalyst 38.

Referring to FIGS. 7 and 8, another embodiment of a catalytic distillation column 310 utilizing packing according to the present invention is depicted. In FIG. 7, a top view of a horizontal tray 30 in this embodiment of the present invention is illustrated. Tray 30 has separation or fractionation, mixing and reaction sections near or at a portion of the midline of the tray.

The separation section includes at least one vapor channel 42. Vapor channel 42 extends horizontally across a width of catalytic distillation column 310. Packing (not shown) is positioned within vapor channel 42 to provide for vapor 32 and liquid 34 separation or fractionation.

Within vapor channel 42, risers 92 are positioned along a length of vapor channel 42. Risers 92 have a chimney depicted by the dotted line with a hat depicted by the solid line. The risers 92 provide a vapor chimney to allow vapor 32 to go to the packing above located within channel 42. The vapor chimney helps to balance pressure between the sections.

Horizontal tray 30 has a liquid mixing deck 48 situated between interior surface 52 of sidewall 16. Feed pipes 70 provide for liquid movement through horizontal tray 30 and mixing deck 48 to the reaction section.

Vapor channel 42 provides for the movement of vapor through liquid mixing deck 48. Reaction product outlet 72 below liquid mixing deck 48 provides for liquid movement from the reaction section below to the separation section of the next tray section.

Referring to FIG. 8, a section W-W through catalytic distillation column 310 of FIG. 7 is illustrated. In this embodiment of the invention, a sequence of spaced apart horizontal trays 30, each with a reaction section 26, a mixing section and a separation section 28, is situated within the catalytic distillation column 310. The sections of tray 30 in this embodiment lie basically in the same plane within column 310.

The separation section includes at least one vapor channel 42. Vapor channel 42 provides for a flow of vapor 32 passing vertically through tray 30 through a liquid mixing deck 48. Packing 86 is situated within the vapor channel 42 for vapor 32 and liquid 34 interaction and mass transfer. A liquid distributor 88 distributes liquid 34 across top surface 90 of packing 86. Packing 86 may be random packing or structured packing or any other type of packing that is known in the art.

After separation and fractionation, liquid 34 exits to a horizontal liquid mixing deck 48 below. Liquid mixing deck 48 extends horizontally between an interior surface 52 of sidewalls 16 in catalytic distillation column 310. After mixing, liquid 34 from liquid mixing deck 48 enters through feed pipes 70 into catalyst chamber 40 of reaction section 28.

Catalytic distillation column 310 has a catalyst chamber 40 with catalyst 38. Catalyst chamber 40 is designed to more evenly distribute the liquid within the reaction section. In this embodiment, catalyst 38 is a packed material and is located within receiving pan 36. Liquid 34 enters the catalyst chamber 40 from feed pipes 70 and is evenly distributed throughout catalyst 38 to react catalytically.

Beneath liquid mixing deck 48, a plurality of reaction product outlets 72 feed liquid from the reaction section 26 to the separation section 28. After the catalytic reaction, liquid 34 exits from open portion 80 of catalyst chamber 40 through reaction product outlet 72 to separation section 28.

The assist in controlling a pressure drop between the sections and within the catalytic distillation column, risers 92 are positioned along a length of vapor channel 42 above liquid mixing deck 48. Risers 92 have a chimney with a hat. The risers 92 provide a vapor chimney to allow vapor 32 to go to the packing above located within channel 42 without being plugged from the falling liquid of the tray above. The vapor chimney helps to balance pressure between the sections.

Referring to FIGS. 9 and 10, an alternate embodiment of catalytic distillation column 410 has multiple catalyst chambers 40, separation sections 28 and reaction sections within tray 30. Tray 30 of this embodiment of catalytic distillation column 410 is operated in a similar manner to that for the embodiment of catalytic distillation column 310.

FIG. 9 is a top view of horizontal tray 30. Tray 30 has separation or fractionation, mixing and reaction sections near or at a portion of a midline plane of the tray. The separation section includes multiple vapor channels 42. Vapor channels 42 extend horizontally across a width of catalytic distillation column 410. Packing (not shown) is positioned within vapor channels 42 to provide for vapor 32 and liquid 34 separation or fractionation. Multiple packing beds 86 are situated within the vapor channels 42 so that vapor bubbles through liquid that is flowing across packing 86 for mass transfer.

Within vapor channels 42, risers 92 are positioned along a length of the vapor channels. Risers 92 have a chimney depicted by the dotted line with a hat depicted by the solid line. The risers 92 provide a vapor chimney to allow vapor 32 to go to the packing above located within channel 42. The vapor chimney helps to balance pressure between the sections.

Horizontal tray 30 has a liquid mixing deck 48 situated between interior surface 52 of sidewall 16 of catalytic distillation column 410. Feed pipes 70 provide for liquid movement through horizontal tray 30 and mixing deck 48 to the reaction section.

Turning to FIG. 10, a vertical section through V-V of FIG. 9 is depicted. In this embodiment, multiple packed beds of catalyst 38, reaction 26 and separation sections 28 with packing 86 are utilized. Horizontal tray 30 has reaction sections 26, mixing sections and multiple separation sections 28.

Separation sections 28 are packed with packing 86. Liquid distributors 88 distributes liquid 34 across top surface 90 of packing 86. Packing 86 may be random packing or structured packing or any other type of packing known in the art.

The separation section includes multiple vapor channels 42. Vapor channels 42 extend horizontally across a width of catalytic distillation column 410. Packing is positioned within vapor channels 42 to provide for vapor 32 and liquid 34 separation or fractionation. Multiple packing beds 86 are situated within the vapor channels 42 so that vapor bubbles through liquid that is flowing across packing 86 for mass transfer.

Within vapor channels 42, risers 92 are positioned along a length of the vapor channels. Risers 92 have a chimney with a hat. The risers 92 provide a vapor chimney to allow vapor 32 to go to the packing above located within channel 42. The vapor chimney helps to balance pressure between the sections.

Horizontal tray 30 has a liquid mixing deck 48 situated between interior surface 52 of sidewall 16 of catalytic distillation column 410. Liquid 34 mixed on liquid mixing deck 48 and is fed into feed pipes 70 provide for liquid movement through horizontal tray 30 and mixing deck 48 to the reaction section.

The reaction of catalytic distillation column 410 has multiple catalyst chambers 40 each with catalyst 38. In this embodiment, multiple beds of catalyst 38 consist of a packed material and are located within a receiving pan. Liquid 34 from the feed pipes 70 is evenly distributed within the reaction section 26 by the catalyst chambers 40.

After a catalytic reaction with the catalyst 38, the liquid 34 rises to open portion 80 of catalyst chamber 40. Beneath liquid mixing deck 48, a plurality of reaction product outlets 72 are situated near a top section of open portion 80 of the catalyst chambers 40 to provide for liquid movement to the next separation section.

Referring now to FIG. 11, a perspective view of a catalytic distillation column is illustrated. In this embodiment of the present invention, a horizontal tray 30, with a reaction section 26, a mixing section and a separation section 28, is situated within the catalytic distillation column. Tray 30 has a catalyst 38 contained within a catalyst chamber 40.

The separation section includes at least one vapor channel 42 positioned horizontally across tray 30. Vapor channel 42 provides for a flow of vapor 32 passing vertically through tray 30. Vertical sidewalls 50 extend along each side for the full length of vapor channel 42. A series of horizontal plates 44 each having holes 46 extends across the width between sidewalls 50 of vapor channel 42. Sidewalls 50 have a height selected so as to maintain a depth of liquid 34 in a bubbling area 68 above plate 44. Optionally, a froth generator or bubble promoter 94 is located at an inlet area 54.

Rising vapor 32 passes through holes 46, as illustrated in FIGS. 3 and 5, so that vapor 32 bubbles through liquid 34 flowing from inlet area 54, across plate 44 in bubbling area 68, as illustrated in FIGS. 2 through 5. Liquid 34 flows over downcorner outlet weir 58 and into a downcorner 56. Liquid 34 then passes over downcorner outlet weir 62 and on to liquid mixing deck 48 below. A combination of tray outlet weir 58 and downcorner outlet weirs 62 also has a pre-designed height to help maintain a depth of liquid 34 in a bubbling area 68 above plate 44.

The mixing section has a liquid mixing deck 48 extending horizontally between an interior surface of sidewalls of the catalytic distillation column and each of opposed sidewalls 50 of vapor channel 42. Liquid mixing deck 48 is situated at a level below the level of corresponding plate 44. Liquid mixing deck 48 has at least one vertical feed pipe 70 to the reaction section below. In this embodiment of the invention, at least one vent 82 to the reaction section below is included to balance pressure between the reaction section 26 and the separation section 28.

Liquid mixing deck 48 is situated directly above catalyst chamber 40 of the reaction section 26. Catalyst chamber 40 contains catalyst 38 for a catalytic reaction. Catalyst chamber 40 is positioned within seal or receiving pan 36 to provide for an even distribution of liquid through the reaction section 26. During column maintenance and/or shutdown, drain hole 96 provides for the draining of any remaining chemicals in the catalytic distillation column. The catalyst chamber 40 is also designed to reduce the pressure drop and minimize the differential between sections and stages. The chamber may have the same pressure as the tray above depending on column-design and desired capacity characteristics.

Liquid 34 flows through vertical feed pipes 70 extending from liquid mixing deck 48 into the catalyst chamber 40. The feed pipe and catalyst chamber combination provides for a proper distribution of reactants throughout the catalyst and reaction bed. This provides for a more efficient reaction and more complete reaction with between the reactant and fractionates where each is concentrated in each stage. In other typical columns, the reactant and products are on different streams leading to reactant bypass and greater plug flow reducing overall efficiency and capacity.

Liquid 34 rises through bed of catalyst 38 within catalyst chamber 40 wherein the reaction mixture reacts catalytically. The level of liquid 34 in catalyst chamber 40 rises to an open portion 80 for liquid flow above catalyst 38, until it reaches a plurality of reaction product outlets 72. Liquid 34 then pours into a liquid transport channel 74.

Liquid 34 travels along liquid transport channel 74 to inlet area 54 of another tray 30 below that tray 30 through which it has just passed. Contact between liquid 34 and catalyst 38 is maximized as there are no bubbles of vapor 32 rising through catalyst chamber 40.

Vertical sheet 76 extending downward from a position above reaction product outlets 72 on sidewalls 50 into the full length of liquid transport channels 74, thus effecting a positive seal preventing movement of vapor 32 in a countercurrent direction to that of liquid 34 through reaction product outlets 72. A vent 82 is provided to allow vapor to exit from open portion 80, thus preventing build up of pressure within open portion 80 resulting from the positive seal.

In an alternate embodiment, a seal is not required if there enough head or column pressure. The seal directs the fluid and balances the pressure for an equalization between the reaction and separation sections. However this may or may not be included if there is a need to isolate the pressure drop differentials depending on the column design needs and requirements.

In an alternate embodiment of the invention demonstrating a reverse-flow within the column (not shown), liquid 34 may flow down through catalyst bed 38. In this embodiment, feed pipe 70 is shortened with catalyst chamber being positioned directly under the liquid mixing deck 48. Feed pipe 70 may also be replaced such that multiple perforations within the liquid mixing deck distributes liquid to the catalyst chamber.

Liquid 34 is distributed above the catalyst bed 28, wherein the reaction mixture reacts catalytically and passes uniformly through the catalyst bed 28 to a lower open portion 80. The liquid 34 then exits from a lower product outlet 72 close to the bottom of the catalyst chamber 40 to the next separation section.

The internals of each of the embodiments of catalytic distillation column 110, 210, 310 and 410 utilize known tray design procedures such as perforated, sieve and valve trays, bubble promoters and single and multiple stage downcorner designs with known and calculable hydraulic conditions of columns utilizing receiving or seal pans. In multiple embodiments of the present invention, catalyst beds are located in receiving pans 36 in the present invention. Catalytic distributors also provide a more even distribution through the reaction section to provide a more comprehensive reaction stage. As a result, our invention provides a more reliable operation, greater column capacity and efficiency.

Features and resulting benefits common to each of catalytic distillation column internals include the following. A combination of catalyst chambers 40 and separation tray components such as plates 44 or packings 86 are situated at the same catalytic distillation tray 30. Liquid flow on separation tray 30 is in the same direction on successive trays 30 (Lewis Case 2), thus providing the best liquid distribution across plate 44 resulting in maximized mass transfer efficiency.

Partitioned multiple catalyst chambers 40 are located in a sealed receiving pan 36 below separation tray 30 and downcorner 56. The geometry of the reaction section 26 provides up-flow liquid phase reaction in reaction chambers 40. There are no bubbles of vapor 32 within the catalyst chamber 40, and so there is optimum contact between liquid 34 and catalyst 38.

Columns 110, 210, 310, 410 operate with high reaction efficiency arising from uniform liquid 34 distribution in multiple catalyst chambers 40. There is utilization of the entire cross-sectional area of inner compartment 18 of columns 110, 210, 310, 410 for reaction and distillation simultaneously, thus providing high processing capacity.

Catalyst chamber 40 is designed for long durability of materials well known in the art. Several modifications to the catalyst chamber may be made without limiting the scope of the present invention.

For example, liquid downflow passing through the catalyst bed may also be included in an embodiment of this invention. In this downflow direction, liquid is distributed above the catalyst bed, and uniformly passes through the catalyst bed within the receiving or seal pan. The liquid then exits from a lower exit point close to the bottom of the catalyst chamber to the next separation stage.

High design flexibility allows for a wide range of reaction area to distillation area ratios (10:1 to 1:10) to match the rate of reaction with the rate of mass transfer. Changes to the tower internal design may be made by those who are skilled in the art to remain within the scope of the present invention. It will also be appreciated to those skilled in the art that the tray embodiments according to the present invention may be installed in new construction, revamp or other tower internal and column designs.

As shown in one embodiment of the present invention, the efficiency of catalytic distillation may be increased by improving the contact between the liquid phase and the catalyst by design and distribution. The catalytic distillation column has a simultaneous catalytic reaction and separation of the reaction mixture which occurs in a continuous cycle wherein there is a constant fractionation, mixing and reaction for each stage in the column.

The performance of the catalytic distillation column is also improved and enhanced by coordinating the separation step of the process with the reaction. The column internals are designed such that the distribution and application of liquid to the reaction zone and separation zones is better controlled and more uniformly applied. This leads to an increased efficiency while maintaining or lowering the total system cost for the tower internals.

All publications and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

While the invention has been described with respect to multiple embodiments, it will be appreciated that other alternative embodiments may be included. For example, with respect to all of the explicitly disclosed embodiments, as well as all other embodiments of the invention, a different distillation system including different tower internal designs and arrangements may be incorporated. Various other column modifications including multiple dehydration stages and extraction columns and using alternate catalysts may be utilized. These and various other modifications can be made to the disclosed embodiment without departing from the subject of the invention.

The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations will be apparent to practitioners skilled in this art. It is intended that the scope of the invention be defined by the following claims and their equivalents. 

1. A catalytic distillation apparatus comprising: a vessel, at least one support deck in at least a portion of the vessel; the support deck having a separation portion; a mixing portion; and a reaction portion, for simultaneous catalytic reaction and fractional distillation.
 2. The catalytic distillation apparatus according to claim 1 wherein the separation portion is a perforated tray for fractional distillation.
 3. The catalytic distillation apparatus according to claim 1 wherein the separation portion is a valve tray for fractional distillation.
 4. The catalytic distillation apparatus according to claim 1 wherein the separation portion is a sieve tray for fractional distillation.
 5. The catalytic distillation apparatus according to claim 1 wherein the separation portion is a packing for fractional distillation.
 6. The catalytic distillation apparatus according to claim 1 wherein the mixing portion has at least one feed pipe through which a liquid reaction mixture descends from the mixing portion to the reaction portion to an at least one receiving pan below the mixing portion.
 7. The catalytic distillation apparatus according to claim 6 wherein the receiving pan has a catalyst for a catalytic reaction.
 8. The catalytic distillation apparatus according to claim 6 wherein the receiving pan has a distributor for uniform distribution of liquid within the reaction portion.
 9. The catalytic distillation apparatus according to claim 1 wherein the reaction portion has a pressure equalizer to balance pressure in the reaction portion with the separation portion.
 9. The catalytic distillation apparatus according to claim 1 wherein the reaction portion has a directional flow seal to balance pressure and distribute liquid from the support deck such that movement of vapor in a countercurrent direction to that of the liquid through the reaction section is prevented.
 10. The catalytic distillation apparatus according to claim 1 wherein the reaction portion has a directional flow seal to balance pressure and distribute liquid from the support deck.
 11. The catalytic distillation apparatus according to claim 1 wherein the separation section has at least one vapor riser extending through the mixing portion, the vapor riser extending above the mixing portion so that liquid does not flow downward through said vapor riser.
 12. A kit for revamping a distillation column comprising: at least one support deck, the support deck having a separation portion, a mixing surface and a reaction portion, for simultaneous catalytic reaction and fractional distillation.
 13. A process for catalytic distillation comprising: feeding a liquid to a vessel having at least one support deck in at least a portion of the vessel; the support deck having a separation portion, a mixing surface and a reaction portion, for simultaneous catalytic reaction and fractional distillation; mixing the liquid on a mixing surface; feeding the liquid to the reaction portion; reacting the liquid with a catalyst through a catalytic reaction in the reaction portion; and fractionating a concentrated product.
 14. The process for catalytic distillation according to claim 13 wherein the feeding the liquid to the reaction portion is even distributed through the reaction portion.
 15. The process for catalytic distillation according to claim 13 wherein the fractionating a concentrated product is by a valve tray.
 16. The process for catalytic distillation according to claim 13 wherein the fractionating a concentrated product is by a sieve tray.
 17. The process for catalytic distillation according to claim 13 wherein the fractionating a concentrated product is by a packed bed.
 18. The process for catalytic distillation according to claim 13 wherein the process further comprises balancing a pressure between the reaction portion and the separation portion. 